US20210013782A1 - Electric Compressor - Google Patents

Electric Compressor Download PDF

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Publication number
US20210013782A1
US20210013782A1 US16/969,921 US201916969921A US2021013782A1 US 20210013782 A1 US20210013782 A1 US 20210013782A1 US 201916969921 A US201916969921 A US 201916969921A US 2021013782 A1 US2021013782 A1 US 2021013782A1
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US
United States
Prior art keywords
inverter
circuit section
control board
sleeve assembly
terminal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US16/969,921
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English (en)
Inventor
Mikio Kobayashi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sanden Corp
Original Assignee
Sanden Automotive Components Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sanden Automotive Components Corp filed Critical Sanden Automotive Components Corp
Assigned to SANDEN AUTOMOTIVE COMPONENTS CORPORATION reassignment SANDEN AUTOMOTIVE COMPONENTS CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KOBAYASHI, MIKIO
Publication of US20210013782A1 publication Critical patent/US20210013782A1/en
Assigned to SANDEN CORPORATION reassignment SANDEN CORPORATION MERGER (SEE DOCUMENT FOR DETAILS). Assignors: SANDEN AUTOMOTIVE COMPONENTS CORPORATION
Abandoned legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/30—Structural association with control circuits or drive circuits
    • H02K11/33—Drive circuits, e.g. power electronics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
    • F04B39/12—Casings; Cylinders; Cylinder heads; Fluid connections
    • F04B39/121—Casings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H1/00—Heating, cooling or ventilating [HVAC] devices
    • B60H1/32—Cooling devices
    • B60H1/3204—Cooling devices using compression
    • B60H1/3205—Control means therefor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B35/00—Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for
    • F04B35/04—Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for the means being electric
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
    • F04B39/14—Provisions for readily assembling or disassembling
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2211/00—Specific aspects not provided for in the other groups of this subclass relating to measuring or protective devices or electric components
    • H02K2211/03—Machines characterised by circuit boards, e.g. pcb

Definitions

  • the present invention relates to an electric compressor in which a motor is incorporated in a housing.
  • an inverter-integrated electric compressor has been used in which an inverter circuit section is installed in an inverter storing section constituted on the outer surface of a housing in consideration of switching noise.
  • an inverter circuit section is installed in an inverter storing section constituted on the outer surface of a housing in consideration of switching noise.
  • the space of the inverter storing section of the electric compressor must be reduced as much as possible, it is also necessary to reduce the volume of the inverter circuit section.
  • the conventional inverter circuit section has a structure in which it is constituted of a high heat radiation board on which a power switching element is mounted, a control board on which a control circuit is executed, and a bus bar assembly, and these are installed in an inverter storing section of a housing in a state in which they are integrated with screws (fasteners). For this reason, a problem arises in that the number of components increases and. miniaturization is also hindered because an insulation distance from the screw must also be secured.
  • the present invention has been made to solve the above conventional technical problems, and an object thereof is to provide an electric compressor capable of reducing the number of components of an inverter circuit section installed in an inverter storing section and also attaining its miniaturization.
  • An electric compressor of the present invention includes a housing having a motor incorporated therein, and an inverter circuit section for supplying power to the motor, and is characterized in that the inverter circuit section includes an inverter control board on which a control circuit is mounted, a resin-made sleeve assembly, and a power module on which power switching elements are mounted, in that the sleeve assembly has positioning pins for the inverter control board and the power module, and the positioning pins are thermally caulked in a state in which the sleeve assembly is sandwiched by the inverter control board and the power module to thereby integrate the inverter control board, the sleeve assembly, and the power module, and in that the integrated inverter circuit section is installed in an inverter storing section constituted on an outer surface of the housing.
  • the electric compressor of the invention of claim 2 is characterized in the above invention in that the sleeve assembly has a terminal connection portion comprised of a male screw having a screw groove, and a sleeve through which a bolt for fixing the inverter circuit section to the housing is inserted, and in that the terminal connection portion and the sleeve are integrally resin-molded in a state in which the screw groove portion is protruded.
  • the electric compressor of the invention of claim 3 is characterized in the above invention in that the screw groove portion of the terminal connection portion passes through the inverter control board to protrude there through, and a connection terminal is interposed by a nut screwed into the screw groove portion and the inverter control board to electrically connect the connection terminal to the inverter control board.
  • the electric compressor of the invention of claim 4 is characterized in that in the above respective inventions, the sleeve assembly has positioning pins for the housing.
  • an electric compressor including a housing having a motor incorporated therein, and an inverter circuit section for supplying power to the motor has a structure in which the inverter circuit section includes an inverter control board on which a control circuit is mounted, a resin-made sleeve assembly, and a power module on which power switching elements are mounted, in which the sleeve assembly has positioning pins for the inverter control board and the power module, and the positioning pins are thermally caulked in a state in which the sleeve assembly is sandwiched by the inverter control board and the power module to thereby integrate the inverter control board, the sleeve assembly, and the power module, and in which the integrated inverter circuit section is installed in an inverter storing section constituted on an outer surface of the housing.
  • the non-use of the fasteners such as the screws makes it unnecessary to secure an insulation distance from them either and enables contribution to downsizing.
  • the resin-made sleeve assembly is interposed between the inverter control board and the power module in the integrated state, the insulation distance between the inverter control board and the power module is ensured to be shortest.
  • the influence of heat generated from the power switching element of the power module on the inverter control board can also be blocked by the resin-made sleeve assembly, miniaturization can be realized also by these.
  • the sleeve assembly is provided with a terminal connection portion comprised of a male screw having a screw groove, and a sleeve through which a bolt for fixing the inverter circuit section to the housing is inserted, and the terminal connection portion and the sleeve are integrally resin-molded in a state in which the screw groove portion is protruded, thereby making it possible to provide a structure high in rigidity and improve vibration resistance.
  • the screw groove portion of the terminal connection portion passes through the inverter control board to protrude there through, and a connection terminal is interposed by a nut screwed into the screw groove portion and the inverter control board to thereby electrically connect the connection terminal to the inverter control board. Consequently, the strength and rigidity of the inverter circuit section around the terminal connection portion to which each of connection terminals of other electric components is connected can be improved.
  • the positioning of the inverter circuit section and the housing can also be easily performed by providing the sleeve assembly with positioning pins for the housing.
  • FIG. 1 is a vertical sectional side view of an inverter-integrated electric compressor of an embodiment to which the present invention is applied;
  • FIG. 2 is a plan view of a state in which a lid member of the electric compressor is detached, as seen from the side (one end side) of an inverter storing section;
  • FIG. 3 is an enlarged vertical sectional side view of a part of the inverter storing section of the electric compressor of FIG. 1 ;
  • FIG. 4 is a perspective view of an inverter circuit section of the electric compressor of the electric compressor of FIG. 1 ;
  • FIG. 5 is a perspective view of a back surface of the inverter circuit section of FIG. 4 ;
  • FIG. 6 is a perspective view of a sleeve assembly of the inverter circuit section of FIG. 4 ;
  • FIG. 7 is a perspective view of a back surface of the sleeve assembly of FIG. 6 ;
  • FIG. 8 is a perspective view of a terminal connection portion of the sleeve assembly of FIG. 6 ;
  • FIG. 9 is a perspective view of a power module of the inverter circuit section of FIG. 4 ;
  • FIG. 10 is a vertical sectional side view of a switching element part of the power module of FIG. 9 ;
  • FIG. 11 is a perspective view of an installation plate of the power module of FIG. 9 ;
  • FIG. 12 is an exploded perspective view of the power module of FIG. 9 ;
  • FIG. 13 is an exploded perspective view of the inverter circuit section of FIG. 4 ;
  • FIG. 14 is a perspective view of a filter circuit section of the electric compressor of FIG. 1 ;
  • FIG. 15 is a perspective view of a back surface of the filter circuit section of FIG. 14 ;
  • FIG. 16 is a perspective view of a support member of the filter circuit section of FIG. 14 ;
  • FIG. 17 is a perspective view of a back surface of the support member of FIG. 16 ;
  • FIG. 18 is a perspective view of a nut member of the filter circuit section of FIG. 14 ;
  • FIG. 19 is a vertical sectional side view of the nut member of FIG. 18 ;
  • FIG. 20 is a perspective view of a filter side connection terminal of the filter circuit section of FIG. 14 ;
  • FIG. 21 is an exploded perspective view of a filter circuit board of the filter circuit section of FIG. 14 and the support member thereof;
  • FIG. 22 is a diagram describing a procedure of attaching the inverter circuit section and the filter circuit section to the inverter storing section of the electric compressor of FIG. 1 ;
  • FIG. 23 is a diagram describing a procedure of attaching the inverter circuit section to the inverter storing section of the electric compressor of FIG. 1 ;
  • FIG. 24 is an enlarged plan view of the inverter storing section at a motor side connection terminal portion of the electric compressor of FIG. 1 ;
  • FIG. 25 is a vertical sectional side view of the inverter storing section at the motor side connection terminal portion of the electric compressor of FIG. 1 ;
  • FIG. 26 is a plan view of a motor side connection terminal of the electric compressor of FIG. 1 ;
  • FIG. 27 is a diagram describing a procedure of attaching the motor side connection terminal of the electric compressor of FIG. 1 ;
  • FIG. 28 is a diagram describing a procedure of attaching the filter circuit section to the inverter storing section of the electric compressor of FIG. 1 ;
  • FIG. 29 is a diagram describing a procedure of attaching power source side connection terminals to the filter circuit section of FIG. 14 ;
  • FIG. 30 is an enlarged perspective view of a state in which the power source side connection terminals are attached to the filter circuit section of FIG. 14 ;
  • FIG. 31 is a perspective view of the filter circuit section of the inverter storing section in the state in which the power source side connection terminals shown in FIG. 29 are attached.
  • FIG. 1 is a vertical sectional side view of an electric compressor 1 according to an embodiment to which the present invention is applied
  • FIG. 2 is a plan view of a state in which a lid member 11 of the electric compressor 1 is detached, as seen from the side (one end side) of an inverter storing section 8
  • FIG. 3 is an enlarged vertical sectional side view of a portion of the inverter storing section 8 of the electric compressor 1 .
  • the electric compressor 1 is a so-called inverter-integrated electric compressor, and. constitutes a part of a refrigerant circuit of a vehicle air conditioning device which conditions air of a vehicle interior of an unillustrated vehicle.
  • the electric compressor 1 includes a motor 6 , a housing 2 in which a compression mechanism 7 to be driven by a rotating shaft 5 of the motor 6 is incorporated, an inverter circuit section 3 which drives the motor 2 , and a filter circuit section 4 as an electric circuit section for absorbing a high frequency component of a switching current.
  • An inverter storing section 8 which is disposed on one end side of the motor 6 in an axial direction of the rotating shaft 5 and serves as a storing section is constituted on the outer surface of the housing 2 in the embodiment.
  • An opening 9 of the inverter storing section 8 is openable closed by the lid member 11 .
  • the inverter circuit section 3 and the filter circuit section 4 are constituted to be stored each individually in the inverter storing section 8 from the axial direction of the rotating shaft 5 of the motor 6 and detachably attached to the housing 2 .
  • the respective figures illustrate the electric compressor 1 of the embodiment in a state in which the inverter storing section 8 is shown on the upside, but in actual, the electric compressor 1 is disposed in a lateral direction so that the inverter storing section 8 is disposed on one side.
  • the motor 6 of the embodiment is constituted of a three-phase synchronous motor (a brushless DC motor) and the compression mechanism 7 is, for example, a scroll type compression mechanism.
  • the compression mechanism 7 is driven by the rotating shaft 5 of the motor 6 to compress a refrigerant, thereby discharging the refrigerant into the refrigerant circuit.
  • a low-temperature gas refrigerant sucked from an evaporator (also referred to as a heat absorber) also constituting a part of the refrigerant circuit flows through the housing 2 . Therefore, the inside of the housing 2 is cooled.
  • the inverter storing section 8 is separated from the inside of the housing 2 in which the motor 6 is housed, by a partition wall 12 which serves as a bottom face of the inverter storing section 8 , and the partition wall 12 is also cooled by the low-temperature gas refrigerant.
  • the inverter circuit section 3 has a power module 14 on which six power switching elements 13 (IGBT in the embodiment) constituting arms of respective phases of a three-phase inverter circuit are mounted, an inverter control board 17 on which a control circuit 16 is mounted, and a resin-made sleeve assembly 18 having a plurality of (five in the embodiment) terminal connection portions 19 , 20 , 21 , 22 , and 23 .
  • IGBT power switching elements
  • the inverter circuit section 3 converts DC power supplied from a battery of the unillustrated vehicle to three-phase AC power to supply the power to a stator coil 27 of the motor 6 . Therefore, connection points between the power switching elements 13 on an upper arm side of each phase and the power switching elements 13 on a lower arm side thereof are respectively connected to lead terminals 24 , 25 , and 26 extending out from the partition wall 12 of the housing 2 and projecting in the axial direction via three motor side connection terminals (connection terminals) 28 . Power source terminals of the power switching elements 13 on the upper arm side and ground terminals of the power switching elements 13 on the lower arm side are connected to a power source harness from the above-described battery via the filter circuit section 4 and a connector (HV connector) 29 for high power.
  • HV connector connector
  • the lead terminals 24 to 26 each of which is connected to the connection point between the power switching element 13 on the upper arm side of each phase and the power switching element 13 on the lower arm side thereof extend through the partition wall 12 to be connected to the stator coil 27 of the motor 6 in the housing 2 .
  • the power source terminals and the ground terminals are electrically connected to the power source harness via the filter circuit section 4 , power source side connection terminals (connection terminals) 31 respectively provided at the leading ends of two wires 98 extending out from the aforementioned high power connector 29 , and the high power connector 29 , and others.
  • the aforementioned five terminal connection portions 19 , 20 , 21 , 22 , and 23 are projected from t..lie sleeve assembly 18 , and the sleeve assembly 18 further has six sleeves 32 .
  • Any of the terminal connection portions 19 to 23 is constituted of a metal-made male screw as shown in FIG. 8 in the embodiment and has an embedded portion 33 (which becomes a screw head) having fine irregularities formed on the outer surface thereof, and a screw groove portion 34 protruding from the embedded portion 33 .
  • the sleeve 32 is made of a metal cylinder having a predetermined length dimension.
  • these terminal connection portions 19 to 23 and the sleeves 32 are resin-molded integrally with the sleeve assembly 18 by insert molding of an insulating hard resin.
  • the embedded portions 33 of the respective terminal connection portions 19 to 23 are embedded into the hard resin of the sleeve assembly 18 , and the screw groove 34 is in a state of being protruded upward from the surface of the sleeve assembly 18 .
  • the terminal connection portions 19 to 21 are arranged at positions on the lead terminals 24 to 26 sides, and the terminal connection portions 22 and 23 are arranged at positions on the filter circuit section 4 side.
  • each sleeve 32 is disposed in a peripheral portion of the sleeve assembly 18 and has upper and lower ends exposed and opened to the surface of the sleeve assembly 18 and its back surface, and enables a bolt 36 for fixing to the housing 2 to be described later to be inserted there through.
  • positioning pins 37 with respect to the inverter control board 17 are three protruded and formed integrally by a hard resin at predetermined positions on the surface of the sleeve assembly 18 .
  • positioning pins 38 with respect to the power module 14 are four protruded and formed integrally by a hard resin at predetermined positions on the back surface of the sleeve assembly 18 .
  • positioning pins 39 with respect to the housing 2 are two protruded and formed integrally by a hard resin at predetermined positions on the back surface of the sleeve assembly 18 .
  • insertion holes 42 for causing terminals 41 for sources, emitters, and drains of the respective power switching elements 13 mounted to the power module 14 to pass there through are formed in plural ( 18 spots) at the center part of the sleeve assembly 18 . Then, as will be described later, the sleeve assembly 18 has a predetermined thickness dimension enough only to allow an insulation distance (the shortest insulation distance) between the inverter control board 17 and the power module 14 (an installation plate 43 to be described later) to be at least ensured.
  • the constitution of the power module 14 will be described with reference to FIGS. 9 to 12 .
  • the power module 14 is constituted by mounting the six power switching elements 13 on the installation plate 43 constituted of a metal plate (aluminum in the embodiment) having high heat radiation.
  • fitting holes 44 exist in the installation plate 43 three by three at predetermined intervals and are formed six in total in two rows to extend there through, and counter bore portions 46 are respectively recess-formed in the surfaces of the respective fitting holes 44 .
  • a male screw 47 is press-fit in and fixed to each fitting whole 44 from the back surface side thereof, and vertically disposed on the installation plate 43 .
  • a screw groove portion 48 thereof protrudes from the surface of the installation plate 43 in its fitted state, and each of resin coating materials 49 is mold-formed on the outer surface of the male screw 47 at the portion other than the screw groove portion 48 of each male screw 47 inclusive of the counter bore portion 46 .
  • the resin coating materials 49 respectively covers the male screws 47 in a state in which the screw groove portions 48 of the male screws 47 are exposed ( FIG. 11 ).
  • the power switching elements 13 are respectively formed with through holes 51 . Then, each power switching element is disposed on the installation plate 43 (its surface) through an insulating sheet 52 in the form to allow each mail screw 47 to penetrate through the through hole 51 .
  • the insulating sheets 52 are two used in the form to extend over the power switching elements 13 of each row.
  • Each insulating sheet 52 is also formed with through holes 53 three by three. Each male screw 47 penetrates through the through whole 53 of the insulating sheet 52 and the through hole 51 of the power switching element 13 , and the screw groove portion 48 protrudes from the power switching element 13 .
  • the terminals 41 of the power switching elements 13 of each row are adjacent to each other in the center part of the installation plate 43 and bent to be directed in an upward direction from the installation plate 43 (in a direction to rise from the surface thereof).
  • a nut 54 is screwed into the screw groove portion 48 of each male screw 47 to thereby fasten and fix each power switching element 13 to the installation plate 43 , thus constituting the power module 14 .
  • the resin covering material 49 is interposed between the power switching element 13 and the insulating sheet 52 and the male screw 47 ( FIG. 10 ).
  • each male screw 47 performs a role of positioning the power switching element 13 and the insulating sheet 52 to the installation plate 43 .
  • each male screw 47 is press-fitted and fixed to the installation plate 43 , and the resin coating material 49 is mold-shaped on the outer surface of the male screw 47 , it is possible to achieve a further improvement in assembly workability and significantly contribute even to an improvement in space saving.
  • insertion boles 56 are five formed at positions corresponding to the predetermined sleeves 32 of the sleeve assembly 18 described above. Further, positioning holes 57 are six formed penetratingly at the positions corresponding to the positioning pins 38 and 39 formed on the back surface of the sleeve assembly 18 .
  • the control circuit 16 of the inverter control board 17 performs switching control of each power switching element 13 of the power module 14 based on an external command. Further, the control circuit has a function of transmitting a drive state of the motor 6 to the outside, and is constituted by connecting each circuit component such as a microcomputer via a printed wire.
  • terminal connection holes 58 are five formed at positions corresponding to the terminal connection portions 19 , 20 , 21 , 22 , and 23 of the sleeve assembly 18 described above.
  • insertion holes 59 are eight formed in the peripheral portion of the inverter control board 17 inclusive of positions corresponding to the respective sleeves 32 of the sleeve assembly 18 .
  • positioning holes 61 are three formed penetratingly at positions respectively corresponding to the positioning pins 37 formed on the surface of the sleeve assembly 18 . Additionally, a plurality of terminal connection holes 62 (18 spots) are formed even at positions corresponding to the respective insertion holes 42 of the sleeve assembly 18 .
  • the inverter circuit section 3 integrates the inverter control board 17 , the sleeve assembly 18 , and the power module 14 in a sub line.
  • the inverter control board 17 on which the control circuit 16 is mounted is taken as the upper side
  • the power module 14 on which each power switching element 13 is mounted is taken as the lower side
  • these inverter control board 17 , sleeve assembly 18 and power module 14 are sequentially stacked in a state in which the sleeve assembly 18 is interposed by these inverter control board 17 and power module 14 .
  • the positioning pins 37 on the surface of the sleeve assembly 18 respectively enter the positioning holes 61 of the inverter control board 17 and protrude from the inverter control board 17 .
  • the positioning pins 38 and 39 on the hack surface of the sleeve assembly 18 respectively enter the positioning holes 57 of the power module 14 and protrude from the power module 14 , so that the positions of the three parties are determined with high accuracy.
  • each insertion hole 56 of the power module 14 corresponds to the back surface side of the five sleeves 32 of the sleeves 32 of the sleeve assembly 18 .
  • the six insertion holes 59 of the insertion holes 59 of the inverter control board 17 correspond to the surface side of each sleeve 32 of the sleeve assembly 18 .
  • the terminal connection portions 19 to 23 provided in the sleeve assembly 18 pass through the terminal connection holes 58 formed in the inverter control board 17 and protrude to the surface side of the inverter control board 17 .
  • terminals 41 of the respective power switching elements 13 of the power module 14 pass through the respective insertion holes 42 of the sleeve assembly 18 and protrude slightly from the terminal connection holes 62 of the inverter control board 17 to the surface side of the inverter control board 17 .
  • each positioning pin. 37 projecting from the inverter control board 17 and each positioning pin 38 projecting from the power module 14 are heat caulked, whereby the inverter control section 17 , the sleeve assembly 18 , and the power module 14 are made integral. Further, the terminal 41 of the power switching element 13 protruding from each terminal connection hole 62 is soldered to the inverter control circuit 17 to electrically connect the power switching element 13 and the inverter control board 17 .
  • the inverter control board 17 , the sleeve assembly 18 , and the power module 14 are integrated in a sub line ( FIGS. 4 and 5 ).
  • the resin-made sleeve assembly 18 has a predetermined thickness dimension, the sleeve assembly 18 serves as a spacer interposed between the inverter control block 17 and the power module 14 .
  • the insulation distance between the inverter control section 17 and the power module 14 is ensured at the shortest.
  • the positioning pins 37 and 38 relative to the inverter control board 17 and the power module 14 are provided on the sleeve assembly 18 , and the positioning pins 37 and 38 are heat-caulked with the sleeve assembly 18 sandwiched between the inverter control board 17 and the power module 14 , whereby the inverter control board. 17 , the sleeve assembly 18 , and the power module 14 are integrated. This therefore eliminates the need for special fasteners such as screws for integrating the inverter control board 17 , the sleeve assembly 18 , and the power module 14 of the inverter circuit section 3 and enables a reduction in the number of components and a reduction in weight to be realized.
  • the fasteners such as the screws
  • the fasteners such as the screws
  • the insulation distance between the inverter control board 17 and the power module 14 is ensured to be shortest.
  • the influence of the heat generated from the power switching element 13 of the power module 14 on the inverter control board. 17 can also be blocked by the resin-made sleeve assembly 18 , miniaturization can be realized also by these.
  • the sleeve assembly 18 is provided with the terminal connection portions 19 to 23 made of the male screws having the screw grooves 34 , and the sleeves 32 into which the bolts 36 for fixing the inverter circuit section 3 to the housing 2 are inserted as will be described later, and the terminal connection portions 19 to 23 and the sleeves 32 are integrally resin-molded with the screw groove portions 34 being protruded. Therefore, the sleeve assembly 18 and the inverter circuit section 3 become a structure high in rigidity, thereby making it possible to improve vibration resistance.
  • the filter circuit section 4 is constituted of a filter circuit board 66 as a circuit board on which electric components such as a relatively large smoothing capacitor (electrolytic capacitor) 63 connected between the power source terminal and the installation terminal of the three-phase inverter circuit, a coil 64 also being relatively large, which is connected to the power source terminal, etc. are mounted, and a support member 67 made of a hard resin which accommodates these capacitor 63 and coil 64 (electric components) therein.
  • a filter circuit board 66 as a circuit board on which electric components such as a relatively large smoothing capacitor (electrolytic capacitor) 63 connected between the power source terminal and the installation terminal of the three-phase inverter circuit, a coil 64 also being relatively large, which is connected to the power source terminal, etc.
  • the support member 67 has one surface which is open, and has a container (case) shape having a depth dimension sufficient to accommodate the smoothing capacitor 63 and the coil 64 which are large as described above.
  • five sleeves 68 each having a predetermined length dimension made of a metal cylinder are resin-molded integrally with the support member 67 by insert molding of an insulating hard resin, exposed on the front and back surfaces of the support member 67 , and made open.
  • two bag-shaped metal nut members 69 having fine irregularities formed on the outer surfaces thereof as shown in FIGS. 18 and 19 are similarly resin-molded integrally with the support member 67 on one end side of the support member 67 , exposed on the surface of the support member 67 and made open. Then, the respective nut members 69 are arranged with predetermined intervals from each other.
  • guide portions 76 are two formed on the edge of the support member 67 at a position corresponding to each nut member 69 so as to be hollowed out to the inner side.
  • the guide portions 76 have a predetermined interval from each other. As will be described later, while restricting positional displacements when the two power source side connection terminals 31 are electrically connected to the filter circuit board 66 , an insulation distance between the power source side connection terminals 31 is secured.
  • filter side connection terminals (connection terminals) 71 are integrally resin-molded on the other end side of the support member 67 in the same manner.
  • Each filter side connection terminal 71 has a flat plate terminal portion 72 having a hole 75 defined therein as shown in FIG. 20 and a soldering portion 73 bent at a right angle from the fiat plate terminal portion 72 .
  • the fiat plate terminal portion 72 protrudes laterally from the support member 67 , and the soldering portion 73 is embedded in the support member 67 so as to protrude from its top surface.
  • a positioning pin 74 is formed to protrude from the bottom face of the support member 67
  • the electric components such as the smoothing capacitor 53 , the coil 64 , etc. are mounted on the back surface side of the filter circuit board 66 .
  • insertion holes 77 are four formed in the peripheral portion of the filter circuit board 66 at positions corresponding to the sleeves 68 of the support member 67 described above.
  • Terminal connection holes 78 are two formed on one end side of the filter circuit board. 66 at positions respectively corresponding to the nut members 69 of the support member 67 .
  • terminal connection holes 79 are two formed on the other end side of the filter circuit board 66 at positions respectively corresponding to the filter side connection terminals 71 of the support member 67 .
  • the filter circuit section 4 also integrates the filter circuit board 66 and the support member 67 in a sub line. At that time, first, as shown in FIG. 21 , the smoothing capacitor 64 and the coil 64 of the filter circuit board 66 are placed on the lower side, and these are accommodated in the support member 67 .
  • the soldering portions 73 of the filter side connection terminals 71 respectively enter the terminal connection holes 79 of the filter circuit board 66 and protrude slightly from the filter circuit board 66 , and the insertion holes 77 respectively correspond to the sleeves 68 of the support member 67 . Further, the terminal connection holes 78 of the filter circuit board 66 respectively corresponds to the nut members 69 of the support member 67 .
  • the filter circuit board 66 and the support member 67 are integrated by filling the support member 67 with a thermosetting resin 81 (for example, an epoxy resin, which is shown in FIG, 3 ). Further, the soldering portion 73 of the filter side connection terminal 71 protruding from each terminal connection hole 79 is soldered to the filter circuit board 66 to be electrically connected to the filter circuit board 66 .
  • the filter circuit board 66 and the support member 67 are integrated in a sub line by filling and soldering of the thermosetting resin 81 like this ( FIGS. 14 and 15 ).
  • the lower end of the sleeve 68 (the end on the housing 2 side) is located at the center in the height direction of the filter circuit section 4 or in a region near the center ( FIG. 3 ).
  • the filter circuit board 66 and the support member 67 are integrated by filling the support member 67 with the thermosetting resin 81 in the sub line in the state in which the smoothing capacitor 63 and the coil 64 are accommodated in the support member 67 of the filter circuit section 4 .
  • the filter side connection terminals 71 whose one ends are soldered to the filter circuit board 66 and whose other ends are electrically connected to the inverter circuit section 3 with the terminal connection portions 22 and 23 (male screws) and nuts 92 as will be described later are resin-molded integrally with the support member 67 .
  • the filter side connection terminal 71 whose one end is soldered to the filter circuit board 66 is resin-molded integrally with the support member 67 , so that it becomes a structure inch high rigidity against vibration, and no stress is generated in the soldering portion even after the filter circuit section 4 is fixed to the housing 2 .
  • FIGS. 22 and 23 a procedure of attaching the inverter circuit section 3 and the filter circuit section 4 to the housing 2 in a main line will be described with reference to FIGS. 22 and 23 .
  • the housing 2 is arranged with one end side in the axial direction of the rotating shaft 5 of the motor 6 in which the inverter storing section 8 is constituted facing upward.
  • the inverter circuit section 3 and the filter circuit section 4 integrated with each other in the sub line are stored each separately in the inverter storing section 8 of the housing 2 similarly from the axial direction (above).
  • positioning recesses 82 are two formed in the partition wall 12 of the housing 2 serving as the bottom face of the inverter storing section 8 at positions corresponding to the positioning pins 39 of the inverter circuit section 3 , respectively.
  • Bolt fixing recesses 83 are eight formed at positions corresponding to the insertion holes 59 of the inverter control board 17 of the inverter circuit section 3 . Then, as each positioning pin 39 enters the positioning recess 82 , the position of the inverter circuit section 3 relative to the housing 2 is determined, and in that state, the insertion holes 59 (the sleeves 32 of the sleeve assembly 18 , the insertion holes 56 of the power module 14 ) respectively correspond to the bolt fixing recesses 83 ( FIG. 22 ).
  • the power switching element 13 is in a heat exchange relationship with the partition wail 12 through the installation plate 43 and is cooled by a low temperature gas refrigerant.
  • 96 is a recess formed in the partition wail 12 to escape the heat caulked positioning pin 38
  • 97 is a recess formed in the partition wail 12 to escape the head of the male screw 47 of the installation plate 43 .
  • positioning recesses 84 are two formed at positions respectively corresponding to the positioning pins 74 of the filter circuit section 4 .
  • Bolt fixing recesses 86 are two formed at positions corresponding to the two insertion holes 77 (sleeves 68 ) at the positions on the side opposite to the inverter circuit section 3 , of the filter circuit section 4 . Then, as each positioning pin 74 enters the positioning recess 84 , the position of the filter circuit 4 is determined with respect to the housing 2 .
  • the filter circuit section 4 and the housing 2 can be easily positioned by providing the support member 67 with the positioning pins 74 for the housing 2 .
  • a part of the upper edge portion of the support member 67 on the inverter circuit section 3 side of the filter circuit section 4 is overlapped with the inverter circuit section 3 , and the two insertion holes (sleeves 68 ) on the inverter circuit section 3 side correspond to the two insertion holes 59 of the inverter circuit section 3 respectively ( FIG. 22 ).
  • a height dimension H 1 of the filter circuit section 4 becomes larger than a height dimension H 2 of the inverter circuit section 3 as shown in FIG. 3 .
  • the filter circuit section 4 large in height dimension can be stored in and attached to the inverter storing section 8 without any trouble.
  • the work of jointly fastening the filter side connection terminals 71 of the filter circuit section 4 (electric circuit section) to the terminal connection portions 22 and 23 of the sleeve assembly 18 with the inverter control board 17 and the nuts 92 can be also easily performed.
  • the sleeves 32 corresponding to the two insertion holes 59 abut against the housing 2 (partition wail 12 ) ( FIG. 3 ).
  • the flat plate terminal portions 72 of the filter side connection terminals 71 of the filter circuit section 4 respectively correspond to the terminal connection portions 22 and 23 of the inverter circuit section 3 , and each of the terminal connection portions 22 and 23 becomes a shape entering into the hole 75 of the flat plate terminal portion 72 of the filter side connection terminal 71 .
  • the bolts 36 are inserted into the insertion holes 59 (sleeves 32 and insertion holes 56 ) of the inverter circuit section 3 and the insertion holes 77 (sleeves 68 ) of the filter circuit section 4 from the axial direction (above) ( FIG. 23 ) , screwed into the bolt fixing recesses 83 and 86 respectively, and then fastened, whereby the inverter circuit section 3 and the filter circuit section 4 are detachably attached to the housing 2 ( FIGS.
  • the respective terminal connection portions 19 , 20 , and 21 of the inverter circuit section 3 are adjacent to the lead terminals 24 , 25 , and 26 respectively, and are protruded in the same axial direction (upward) as the lead terminals 24 , 25 , and 26 .
  • the motor side connection terminal 28 is made of a metal plate, and as shown in FIG. 26 , has a flat plate terminal portion 88 having a hole 87 defined on one end side, and a pressure contact terminal portion 89 having predetermined elasticity on the other end side.
  • the three motor side connection terminals 28 are inserted into the inverter storing section 8 from the axial direction (above) of the housing 2 , and the lead terminals 24 , 25 , and 26 are respectively press-fit into the pressure contact terminal portions 89 of the motor side connection terminals 28 . Consequently, the pressure contact terminal portion 89 of each motor side connection terminal 28 is pressed against and electrically connected to each of the lead terminals 24 to 26 .
  • terminal connection portions 19 , 20 , and 21 are made to enter into the holes 87 of the flat plate terminal portions 88 , so that the motor side connection terminals 28 are mounted between the lead terminal 24 and the terminal connection portion 19 , the lead terminal 25 and the terminal connection portion 20 , and the lead terminal 26 and the terminal connection portion 21 respectively.
  • each motor side connection terminal 28 is fastened to each of the terminal connection portions 19 to 21 via the inverter control board 17 .
  • each motor side connection terminal 28 is fixed and electrically connected to the inverter control board 17 , and the lead terminals 24 to 26 from the motor 6 are electrically connected to the inverter control board 17 by the motor side connection terminals 28 .
  • the nuts 92 are respectively screwed even into the screw groove portions 34 of the terminal connection portions 22 and 23 of the inverter circuit section 3 from above to thereby sandwich the flat plate terminal portions 72 of the filter side connection terminals 71 between the nuts 92 and the inverter control board 17 , whereby the flat plate terminal portions 72 and the inverter control board 17 are fastened together.
  • the filter side connection terminals 71 are fixed and electrically connected to the inverter control board 17
  • the filter circuit board 66 of the filter circuit section 4 is electrically connected to the inverter control board 17 via the filter side connection terminals 71 .
  • the inverter control board 17 and the filter side connection terminals 71 of the filter circuit section 4 are jointly fastened to the terminal connection portions 22 and 23 by the nuts 92 each screwed into the screw groove portion 34 , and the inverter control board 17 and the filter circuit section 4 are electrically connected, so that the inverter control board 17 and the filter circuit section 4 can be connected with a highly rigid connection structure. Further, the inverter circuit section 3 and the filter circuit section 4 can be easily connected to each other and attached and removed to and from the housing 2 .
  • the filter side connection terminals 71 of the filter circuit section 4 can be directly connected to the inverter control board 17 , it is possible to suppress costs by reducing the number of components.
  • assembling and removal become easier than solder connection, and the sleeve assembly 18 and the inverter control board 17 are also integrated by being fastened together by the nuts 92 , so that the rigidity of the inverter control board 17 can also be improved.
  • the two power source side connection terminals 31 described above are also flat plate terminals with holes 94 defined therein, and the holes 94 are made to correspond to the respective terminal connection holes 78 of the filter circuit section 4 .
  • the screws 93 are inserted from the axial direction (above) and screwed into the nut members 69 , whereby the power source side connection terminals 31 and the filter circuit board 66 are fastened together to the nut members 69 . Consequently, the filter circuit board 66 and the power source side connection terminals 31 are electrically connected.
  • the bag-shaped nut members 69 are integrally resin-molded on the support member 67 of the filter circuit section 4 , the filter circuit board 66 and the power source side connection terminals 31 are fastened together to the nut members 69 with the screws 93 , and the filter circuit board 66 and the power source side connection terminals 31 are electrically connected. It is thus possible to connect the filter circuit board 66 and the power source side connection terminals 31 with a highly rigid connection structure.
  • the power source side connection terminals 31 can be directly connected to the filter circuit board 66 , it is possible to suppress costs by reducing the number of components.
  • assembling and removal become easier than solder connection, and the support member 67 and the filter circuit board 66 are also integrated by fastening together by the screws 93 , so that the rigidity of the filter circuit board 66 can also be improved.
  • the power source side connection terminals 31 respectively enter into and are held by the guide portions 76 formed on the support member 67 ( FIG. 30 ). Thereby, since the positional displacement of each power source side connection terminal 31 is restricted, screwing workability is also improved, and the insulation distance between the power source side connection terminals 31 is also secured ( FIG. 31 ). Then, finally, the lid member 11 is detachably attached to the opening 9 of the inverter storing section 8 , and the opening 9 of the inverter storing section 8 is closed in an openable/closable manner ( FIG. 1 ).
  • the inverter control board 17 , the sleeve assembly 18 , and the power module 14 of the inverter circuit section 3 are integrated and the filter circuit board 66 and the support member 67 of the er circuit section 4 are integrated, and the inverter circuit section 3 and the filter circuit section 4 are stored each individually in the inverter storing section 8 from the same direction and detachably attached to the housing 2 . Therefore, the inverter circuit section 3 and the filter circuit section 4 can be stored each separately in the inverter storing section 8 , whereby the degree of freedom in the assembling process when the inverter circuit section 3 and the filter circuit section 4 are attached to the housing 2 can be increased, and the assembly workability of the electric compressor 1 can be improved.
  • the soldering of the inverter circuit section 3 since the soldering of the inverter circuit section 3 , the soldering of the filter circuit section 4 , and the resin filling can be performed in the sub line before the assembly to the housing 2 , man-hours in the main line can be reduced. Further, since the inverter circuit section 3 and the filter circuit section 4 are provided separately, the degree of freedom in design is increased in their arrangement, and the space for the inverter storing section 8 can be saved. Furthermore, since the relatively large filter circuit section 4 is provided separately from the inverter circuit section 3 , vibration resistance is also improved, and the filter circuit section 4 is extremely suitable as for an electric compressor used in a vehicle air conditioning device.
  • the inverter circuit section 3 and the filter circuit section 4 can be stored in the inverter storing section 8 from the same direction, there is no need to change the orientation of the housing 2 when attaching the inverter circuit section 3 and the filter circuit section 4 to the housing 2 , and the assembly work becomes even better.
  • the inverter storing section 8 is constituted on one end side of the housing 2 in the axial direction of the rotating shaft 5 of the motor 6 , and the inverter circuit section 3 and the filter circuit section 4 are stored each individually in the inverter storing section 8 from the axial direction of the rotating shaft 5 of the motor 6 and detachably attached to the housing 2 . Consequently, the inverter circuit section 3 and the filter circuit section 4 can be easily Installed in the inverter storing section 8 from above with the one end side of the housing 2 facing upward as described above.
  • the motor side connection terminals 28 connected to the lead terminals 2 - 4 to 26 of the motor 6 and the filter side connection terminals 71 of the filter circuit section 4 are fixed to the terminal connection portions 19 to 23 of the sleeve assembly 18 , respectively, and electrically connected to the inverter control board 17 . Therefore, the electrical connection of the inverter control board 17 , the motor 6 , and the filter circuit section 4 can also be performed without any trouble.
  • the motor side connection terminals 28 connected to the inverter control board 17 and the lead terminals 24 to 26 of the motor 6 are jointly fastened to the terminal connection portions 19 to 23 by the nuts 91 screwed into the screw groove portions 34 , and the inverter control board 17 and the lead terminals 24 to 26 are electrically connected. Consequently, the motor side connection terminals 28 connected to the lead terminals 24 to 26 of the motor 6 can be connected to the inverter control board 17 with a highly rigid connection structure.
  • each of the terminal connection portions 19 to 23 is constituted of the male screw having the screw groove portion 34 , the sleeve assembly 18 is taken to be resin-molded, and the respective terminal connection portions 19 to 23 are integrally resin-molded in the protruded state of each screw groove portion 34 . Therefore, the rigidity of the sleeve assembly 18 and the terminal connection portions 19 to 23 is increased, and the vibration resistance is remarkably improved.
  • the motor side connection terminals 28 and the filter side connection terminals 71 are fastened to the respective terminal connection portions 19 to 23 via the inverter control board 17 by the nuts 91 and 92 screwed into the screw groove portions 34 of the terminal connection portions 19 to 23 .
  • the motor side connection terminals 28 and the filter side connection terminals 71 can be firmly fastened to improve the connection strength and rigidity and to make a constitution resistant to vibration.
  • the sleeve 32 is integrated with the sleeve assembly 13 by inter rally resin-molding the sleeve 32 into which the bolt 36 for fixing the inverter circuit section 3 to the housing 2 is inserted in the sleeve assembly 18 as in the embodiment.
  • the number of components can be reduced and the rigidity of the inverter circuit section 3 can be improved.
  • the terminal connection portions 19 to 21 having the screw groove portions 34 are protrusively provided.
  • the motor side connection terminals 28 are provided with the fiat plate terminal portions 38 , and the fiat plate terminal portions 83 are fixed to the inverter control board 17 of the inverter circuit section 3 by the nuts 91 each screwed into the screw groove portion 34 of the terminal connection portions 19 to 21 , whereby they are electrically connected to the inverter circuit section 3 . Consequently, the motor side connection terminals 28 and the inverter circuit section 3 are mechanically fastened, and the connection strength between the motor side connection terminals 28 and the inverter circuit section 3 can be maintained even when an external force is applied by vibration or heat or the like.
  • the terminal connection portions 19 to 21 are resin-molded integrally with the sleeve assembly 18 with the screw groove portions 34 being protruded.
  • the screw groove portions 34 passes through the inverter control board 17 to protrude there through, and the nuts 91 are screwed into the screw groove portions 34 of the terminal connection portions 19 to 21 , whereby the fiat plate terminal portions 88 of the motor side connection terminals 28 are respectively sandwiched between the nuts 91 and the inverter control board 17 , and in this state, the fiat plate terminal portions 88 are electrically connected to the inverter control board 17 . It is therefore possible to improve the strength and rigidity of the inverter circuit section 3 around the terminal connection portions 19 to 21 to which the motor side connection terminals 88 are connected.
  • the motor side connection terminals 28 are provided with the pressure contact terminal portions 89 which are in pressure contact with and electrically connected to the lead terminals 24 to 26 of the motor 6 , the side of the lead terminals 24 to 26 is subjected to pressure contact as in the related art to enable the motor side connection terminals 28 to be easily connected thereto.
  • the terminal connection portions 19 to 21 protrude in the same direction as the lead terminals 24 to 26 in the state in which the inverter circuit section 3 is stored in the inverter storing section 8 , the direction in which the pressure contact terminal portions 89 of the motor side connection terminals 28 are connected to the lead terminals 24 to 26 of the motor 6 by pressure contact, and the direction in which the flat plate terminal portions 88 are fixed to the terminal connection portions 19 to 21 of the inverter circuit section 3 with the nuts 91 coincide (connection and fixing from above), so that the work of assembling the motor side connection terminals 28 is improved.
  • the sleeve assembly 18 is provided with the positioning pins 39 for the housing 2 , the positioning with the housing 2 when the inverter circuit section 3 is attached to the inverter storing section 8 can be easily performed.
  • the sleeves 68 each having the predetermined length dimension through which the bolts 36 for fixing the filter circuit section 4 to the housing 2 are inserted are resin-molded integrally with the support member 67 of the filter circuit section 4 , and the filter circuit section 4 is fixed to the housing 2 by the bolts 36 in the state in which the sleeves 68 are in contact with the housing 2 . Therefore, the position where the filter circuit section 4 contacts the housing 2 approaches the partition wall 12 side of the housing 2 by the length dimension of the sleeve 68 as shown in FIG. 3 . Consequently, it is possible to reduce the vibration of the filter circuit section 4 when vibration during traveling of the vehicle is applied to the electric compressor 1 and suppress inconvenience that breakage occurs in each part.
  • each sleeve 68 on the housing 2 side is positioned in the center in the height direction of he filter circuit section 4 or the region in the vicinity of its center, thereby making it possible to effectively reduce the vibration of the filter circuit section 4 when the vibration is applied.
  • the shapes and structures of the inverter circuit section 3 , the filter circuit section 4 , and the housing 2 shown in the embodiment are not limited to those, and needless to say, various changes can be made within the scope not departing from the spirit of the present invention.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Inverter Devices (AREA)
  • Compressor (AREA)
US16/969,921 2018-02-23 2019-01-21 Electric Compressor Abandoned US20210013782A1 (en)

Applications Claiming Priority (3)

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JP2018031184A JP6936168B2 (ja) 2018-02-23 2018-02-23 電動圧縮機
JP2018-031184 2018-02-23
PCT/JP2019/002605 WO2019163411A1 (ja) 2018-02-23 2019-01-21 電動圧縮機

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CN (1) CN111712641B8 (zh)
DE (1) DE112019000420T5 (zh)
WO (1) WO2019163411A1 (zh)

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JP7334595B2 (ja) 2019-11-28 2023-08-29 株式会社豊田自動織機 電動圧縮機
JP2021169788A (ja) * 2020-04-15 2021-10-28 株式会社豊田自動織機 電動圧縮機
JP2023120940A (ja) * 2022-02-18 2023-08-30 サンデン株式会社 電動圧縮機
JP2023122007A (ja) * 2022-02-22 2023-09-01 サンデン株式会社 電動圧縮機

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Publication number Publication date
JP6936168B2 (ja) 2021-09-15
JP2019143607A (ja) 2019-08-29
CN111712641A (zh) 2020-09-25
CN111712641B (zh) 2022-02-22
WO2019163411A1 (ja) 2019-08-29
CN111712641B8 (zh) 2022-03-22
DE112019000420T5 (de) 2020-10-01

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